138 Treffer

Long fiber reinforced plastics with thermoplastic resin were steadily growing with an
ongoing success over many industries mainly automotive. Even during economically
difficult periods, they increased their output and their market share.
In addition to flow compression molding, semi-finished LFRT in form of granules were
introduced to new processes like injection molding.
This work covers two major topics to enlarge the performance of LFRTs. Firstly, it
shows a material development, which leads to flame retarded LFRT. Secondly, it
presents a new process method to improve especially dynamic mechanical properties
by laminating two compression molded sheets with no additional equipment.
One major restriction for further applications is represented by flammability of thermoplastics.
This thesis gains for a new potential. Encountering future legislative restrictions
a combination of halogen-free flame retardant and LFRT based on polypropylene
has been developed. Test results match the requirements in accordance to
flammability test UL 94 V0 (2.6 mm). Furthermore the mechanical properties
achieved a similar performance as standard-LFRTs. The polymer flow in compression
molding provokes a fiber orientation parallel to the direction of the flow front development.
A x-ray analysis in combination with a fiber orientation analysis show, that
rheology has a strong influence on the flow front development, fiber orientation and
compression work needed.
One advantage of flow compression molding is the free option in placing the polymer
melts in the cavity. The common mold design with male and female mold without slides
allows changing part thickness by different polymer melt volumes charged in the
cavity. This allows to proceed the compression molding process twice without demolding the first part. On a flat panel, the process of laminating two sheets by compression
molding is demonstrated. A first panel gets over molded by a second polymer
melt. This laminate provides a better performance than a singular molded panel
of the same thickness.
The higher substrate’s temperature the better is the adhesion of the first to the second
layer. Additionally, the best adhesion is achieved in the area of the second polymer
melt cavity placement. Furthermore an optimum in mechanical properties can be
obtained utilizing the same resin for the first and the second layer. A more advanced
material is shown with the combination of a standard-LFRT layer and a flame retarded
layer.
Calculations show, that the flame retardancy of LFRT on polypropylene can be economically
advantageous in comparison to the utilization of higher flame resistant polymer
for large parts. Nevertheless for each specific geometry as well as for certain
mechanical demands an evaluation on the best material to fit has to be carried out.
This work shows economically reasonable options either to improve the mechanical
performance and to enlarge materials properties by flame retardancy or to combine
both.

The popularity of composite materials is constantly growing, which can be verified by
the rising number of composite parts in our everyday life. Examples of composite
parts can be found in the Airbus A 380 or the constantly increasing number of wind
turbines which contain composite rotor blades of over 50m length. Because of the
main features of composites, which are light weight combined with high strength and
the possibility of tailoring the strength and the stiffness of the composite according to
the requirements, their application is highly efficient and economic.
In order to manufacture a composite part by employing a Liquid Composite Molding
Process (LCM), it is first necessary to select an appropriate manufacturing process
such as the Resin Transfer Molding Process (RTM) and to design a mold which corresponds
to the requirements of the selected process. Then the stacking sequence of
the individual fibrous reinforcements is designed to withstand the loads on the final
part. To achieve an efficient composite manufacturing process, pre-shaped, handable,
dry reinforcing structures, so called preforms, need to be applied. Such preforms
can be assembled either by using conventional binder technologies or by the
recently developed “cut and sew approach”. A variety of available software simulation
tools support the design engineer in this task. These tools are, on the one hand, a
fast way of gaining information about the expected loads the mold has to endure during
the injection process. On the other hand, they provide the possibility to optimize
the injection process and its process parameters and to identify critical points of incomplete
saturation. With this information at hand, the design of the mold can be adjusted
in order to obtain optimal processing conditions for a slim and efficient production
cycle.
A prerequisite for employing these powerful simulation tools is to obtain thorough
knowledge of the required input parameters concerning the fibrous reinforcement to
be used. The most important input parameters are the compaction behavior and the
permeability of the fibrous stacking sequence. Because of the absence of modelbased
tools to provide this input information experimental determination methods
have to be employed.
This work introduces two semi-automated measurement cells which determine the inplane
permeability of fibrous reinforcements in an efficient manner, i.e. the dielectrical permeability work cell and the optical compaction and permeability work cell. The
latter of which can determine both the required compaction and the permeability information
in one single experiment. The design and manner of operating of the optical
compaction and permeability work cell is described and its functionality is validated
by a comparison of experimental results.

The introduction to the topic is a description of the techno-economic evolution of
composites. Apart from this, today’s market state of the art of composites is also explained.
As a conclusion, the principal trend towards the higher quality by the increased
application of carbon fibers is ascertained. In particular, it is pointed out that
the restraints of the market growth are mainly caused by the high price, most notably,
of the fiber materials. This situation, in connection with the maturation of the composite
manufacturing processes, demands the need of a cost calculation tool.
In the second step, former composite cost models and their implementations into
software – if available – are described and benchmarked. As a result it is proposed to
combine, different approaches because of their fundamental potential as well as the
deficits. It is suggested to use a resource-based methodology combined with the
PBKM (prozessbasierte Kostenmodellierung = process-based cost modelling) and to
implement the models in a cost calculation software.
The first aim is an economic process analysis which is carried out to receive an abstract
and modular system. Thereby, it is possible to describe the production processes
by successive refinement more and more detailed. The process is divided in
multiple steps which are itself subdivided in technical activities or handlings. The
relevant cost objects with the identifiable cost positions are assigned to those handlings.
This approach assures modularity and offers the possibility of an easy software
implementation. In addition, the functionality of this methodology is demonstrated
considering the two examples “thermoplastic tape placement” and “continuous
pressing”. For that reason these composite manufacturing techniques are analyzed
and the structure is mapped within the use of suggested methodology.
The next topic deals with the modelling of the cycle time for the thermoplastic tape
placement with the use of the PBKM. Within this methodology the derivation of the
cycle time depends only on physical process parameters, which results in a geometrical
complexity based model. The developed model is verified by comparing of the
theoretically derived values with practical experiments. Along with this, the assumptions
for this model are revised and verified. As a technical enhancement of the tape
placement process, different designs of a geometry-adaptive consolidation role are introduced. This technical extension of the process technology is necessary for the
final verification of the model. The new consolidation unit enables to move all geometrical
degrees of freedom and complexities with the same laminate quality. Finally,
a possibility to transfer the methodology of the PBKM to other technologies is proved.
Therefore, it is offered a modus operandi how the continuous pressing technique can
be modelled with the help of the PBKM.
The last chapter deals with the cost calculation tool concerning the structural configuration,
design, and functionality of the software. It is the consequential synthesis of
the results of the economic process analysis and the cycle time models. The practicability
of the modularity is proved by its application in the design phase of the software
and by the integration of the modelling into the tool. The developed cost calculation
software for composite manufacturing processes offers a standardization of the
inputs and calculation algorithms by the use of introduced process analysis, the subdivision
into smallest units. The cycle time calculation models are process specific
know-how which can easily be used unlike an expert's system. The separation of the
single functional entities assures a stringent data management, possibilities for the
advancement, and furthermore, the variableness of representation and reuse of the
derived data. The functionality of the cost tool concerning evaluations and comparisons
are pointed out with two case studies. Plus, the postulated transferability of the
methodology on other composite technologies is demonstrated. The main advantage
of this system is that the modelling offers economical statements of different process
variations without experimentation. Besides, the values ascertained by the PBKM are
more precise compared to other existing models. Therefore, the PBKM can be the
basis for investment decisions like technology change or modifications and helps to
identify techno-economic limitations and potentials.
This version of the cost calculation software offers only the standard repertoire of
cost evaluations and comparisons which turn out to be upgradeable. Thus, there exists
potential to enhance the functionality concerning sensitivity analyses, the integration
of cycle time models for other composite processing technologies, and further
possibilities for the graphic processing. As a conclusion the software with the combination
of different attempts offers a good starting position with respect to the current
evolution status and should be extended.

In the Iranian public media, it was widely reported that by the end of 2004, 380 hectares of the eastern farthest end of the Peninsula Mianqala (northern part of Iran, located in the southeastern coasts of Caspian Sea) were sold to an organisation – the result is that "Asurada" Island will be turned into a so-called “Tourist Village”. The decision has been made and civil works are to begin. The village planned as a new settlement is specifically considered to work with Mianqala, which since June 1976 is an international biosphere reserve and since 1969, an Iranian nature protected area. Considering the special condition of the region as a biosphere reserve, this paper introduces the current situation of the Island Āŝūrāda and the suggested program by the aforementioned organisation. Subsequently, it tries to find an optimal answer to the question of whether "Āŝūrāda" is appropriate for such a purpose and how far it is allowed to be interfered with, through this new settlement. The paper asserts for this development, there is consideration of the settlement’s urban and architectural concept; subsequently analysis is conducted for the spatial development of the settlement, in terms of its influences on the ecological sources, the rural structure and the financial as well as social aspects. Such study is required, particularly due to the chain of tourist influences, which certainly will introduce a new pattern of urban character in terms of quality and quantity. Finally, with the assistance of the case presented, this paper poses the question of whether a new urban pattern like this can endanger a traditional and above all a nature protected context or not.